Ear cushion development is critical for three reasons: comfort, on-head stability, and passive attenuation. While foam is an apparent option for ear cushions, Dyson engineers looked deep into the composition of several foams to determine the best ideal material based on density, compression rate, and spring-back rate – all of which affect how pressure is translated onto the head. When selecting the ideal foam for the ear and headband cushions, it was crucial to strike a balance between comfort, stability when moulded to the ear, and most importantly, acoustic advantage. Moulding around the ear expands the contact points, resulting in improved sealing – and preventing more urban noise from entering the ear. The cushion is designed to be flatter than standard ear cushions for increased attenuation and comfort, and the cushions are oriented to match the position of the ear on the head for best comfort.
A global effort
The Dyson Zone air-purifying headphones were developed by teams in the United Kingdom, Singapore, Malaysia, and China, with a special emphasis on software development on our South East Asia campuses. The creation and integration of the app was important to ensuring a seamless connecting process and providing clever, relevant features for tracking air and noise pollution. Robustness and durability are critical characteristics of a product that is worn outside the home. As is the case with all Dyson devices, the Dyson Zone air-purifying headphones have been subjected to rigorous testing – including temperature-controlled chambers, drop testing, material and fabric wear testing, and button robustness. Our skilled test engineers at the Dyson Malaysia Development Centre, as well as the geography, contribute to this by putting the vacuum cleaner through its paces in warmer weather and higher humidity than in the UK.
